Applicability of Bobbin Tool Friction Stir Welding for Dissimilar Al-Mg Joint

Harshadkumar H. Jadav; Vishvesh J. Badheka; Kishan Fuse; Kush Mehta; Gautam Upadhyay

doi:10.1007/978-981-33-4176-0_18

Applicability of Bobbin Tool Friction Stir Welding for Dissimilar Al-Mg Joint

Harshadkumar H. Jadav^*
, Vishvesh J. Badheka
, Kishan Fuse
, Kush Mehta
, Gautam Upadhyay

^*Corresponding author for this work

Design, Manufacturing And Engineering Management

Research output: Chapter in Book/Report/Conference proceeding › Chapter

1 Citation (Scopus)

Abstract

Stringent material property demand for fuel economy in automobile and aerospace industry can be addressed only by either reducing weight or improving efficiency of the engine. Structural weight reduction requires dissimilar materials with varying thickness and geometry to be joined. Friction stir welding (FSW) is one of the latest additions to the joining processes. Bobbin tool friction stir welding (BTFSW) is a novel derivative of FSW process utilizing two shoulders for even heat distribution with advantage of eliminating backup support. This paper reports conventional FSW and feasibility trials of BTFSW for similar aluminum alloy (AA6061-T6), similar magnesium alloy (AZ31B) and dissimilar aluminum alloy (AA6061-T6) to magnesium alloy (AZ31B). Conventional FSW trials report successful welds without any observable surface defects. However, BTFSW weld surface presents defects like flash and groove, and material sticking to the tool pin is observed. Pin length, bigger diameter of the lower shoulder and flat surface of tool shoulder without chamfered edge are considered to be responsible for flash and groove defects. Process parameters which could have restricted joint formation are discussed. Though these feasibility trials of dissimilar aluminum and magnesium alloy BTFSW achieved limited success, it paves a path for successful joining using BTFSW.

Original language	English
Title of host publication	Lecture Notes in Intelligent Transportation and Infrastructure
Subtitle of host publication	Proceedings of ICRAM 2020
Editors	Ajit Kumar Parwani, PL. Ramkumar, Kumar Abhishek, Saurabh Kumar Yadav
Publisher	Springer Nature
Pages	223-232
Number of pages	10
ISBN (Electronic)	9789813341760
ISBN (Print)	9789813341753
DOIs	https://doi.org/10.1007/978-981-33-4176-0_18
Publication status	Published - 1 Mar 2021
Event	2nd International Conference on Recent Advances in Mechanical Infrastructure - ICRAM 2020 : Recent Advances in Mechanical Infrastructure - Department of Mechanical Engineering, IITRAM, Ahmedabad, India Duration: 21 Aug 2020 → 23 Aug 2020

Publication series

Name	Lecture Notes in Intelligent Transportation and Infrastructure
Publisher	Springer
Volume	Part F1363
ISSN (Print)	2523-3440
ISSN (Electronic)	2523-3459

Conference

Conference	2nd International Conference on Recent Advances in Mechanical Infrastructure - ICRAM 2020
Abbreviated title	ICRAM 2020
Country/Territory	India
City	Ahmedabad
Period	21/08/20 → 23/08/20

Funding

Acknowledgements The authors would like to thank the Student Research Program of Office of Research & Sponsored Program, Pandit Deendayal Petroleum University (PDPU), Gandhi-nagar, India, for providing necessary support and infrastructure to carry out this work under project No.: ORSP/R&D/SRP/2019-20/1454/61. The processing of samples was undertaken on a Vertical Machining Center procured under funding from the Indian Space Research Organisation, Department of Space, Government of India, Bangalore (in collaboration with Space Application Center, Ahmedabad) under the RESPOND program (Project number-ISRO/RES/4/567/09-10).

Keywords

aluminum alloy
bobbin tool FSW
dissimilar welding
magnesium alloy
reducing weight
friction stir welding (FSW)
bobbin tool friction stir welding (BTFSW)

Access to Document

10.1007/978-981-33-4176-0_18

Cite this

Jadav, H. H., Badheka, V. J., Fuse, K., Mehta, K., & Upadhyay, G. (2021). Applicability of Bobbin Tool Friction Stir Welding for Dissimilar Al-Mg Joint. In A. K. Parwani, PL. Ramkumar, K. Abhishek, & S. K. Yadav (Eds.), Lecture Notes in Intelligent Transportation and Infrastructure: Proceedings of ICRAM 2020 (pp. 223-232). (Lecture Notes in Intelligent Transportation and Infrastructure; Vol. Part F1363). Springer Nature. https://doi.org/10.1007/978-981-33-4176-0_18

Jadav, Harshadkumar H. ; Badheka, Vishvesh J. ; Fuse, Kishan et al. / Applicability of Bobbin Tool Friction Stir Welding for Dissimilar Al-Mg Joint. Lecture Notes in Intelligent Transportation and Infrastructure: Proceedings of ICRAM 2020. editor / Ajit Kumar Parwani ; PL. Ramkumar ; Kumar Abhishek ; Saurabh Kumar Yadav. Springer Nature, 2021. pp. 223-232 (Lecture Notes in Intelligent Transportation and Infrastructure).

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title = "Applicability of Bobbin Tool Friction Stir Welding for Dissimilar Al-Mg Joint",

abstract = "Stringent material property demand for fuel economy in automobile and aerospace industry can be addressed only by either reducing weight or improving efficiency of the engine. Structural weight reduction requires dissimilar materials with varying thickness and geometry to be joined. Friction stir welding (FSW) is one of the latest additions to the joining processes. Bobbin tool friction stir welding (BTFSW) is a novel derivative of FSW process utilizing two shoulders for even heat distribution with advantage of eliminating backup support. This paper reports conventional FSW and feasibility trials of BTFSW for similar aluminum alloy (AA6061-T6), similar magnesium alloy (AZ31B) and dissimilar aluminum alloy (AA6061-T6) to magnesium alloy (AZ31B). Conventional FSW trials report successful welds without any observable surface defects. However, BTFSW weld surface presents defects like flash and groove, and material sticking to the tool pin is observed. Pin length, bigger diameter of the lower shoulder and flat surface of tool shoulder without chamfered edge are considered to be responsible for flash and groove defects. Process parameters which could have restricted joint formation are discussed. Though these feasibility trials of dissimilar aluminum and magnesium alloy BTFSW achieved limited success, it paves a path for successful joining using BTFSW.",

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note = "Funding Information: Acknowledgements The authors would like to thank the Student Research Program of Office of Research \& Sponsored Program, Pandit Deendayal Petroleum University (PDPU), Gandhi-nagar, India, for providing necessary support and infrastructure to carry out this work under project No.: ORSP/R\&D/SRP/2019-20/1454/61. The processing of samples was undertaken on a Vertical Machining Center procured under funding from the Indian Space Research Organisation, Department of Space, Government of India, Bangalore (in collaboration with Space Application Center, Ahmedabad) under the RESPOND program (Project number-ISRO/RES/4/567/09-10). Publisher Copyright: {\textcopyright} 2021, The Author(s), under exclusive license to Springer Nature Singapore Pte Ltd. Jadav, H.H., Badheka, V.J., Fuse, K., Mehta, K., Upadhyay, G. (2021). Applicability of Bobbin Tool Friction Stir Welding for Dissimilar Al-Mg Joint. In: Parwani, A.K., Ramkumar, P., Abhishek, K., Yadav, S.K. (eds) Recent Advances in Mechanical Infrastructure. Lecture Notes in Intelligent Transportation and Infrastructure. Springer, Singapore. https://doi.org/10.1007/978-981-33-4176-0\_18 ; 2nd International Conference on Recent Advances in Mechanical Infrastructure - ICRAM 2020 : Recent Advances in Mechanical Infrastructure, ICRAM 2020 ; Conference date: 21-08-2020 Through 23-08-2020",

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Jadav, HH, Badheka, VJ, Fuse, K, Mehta, K & Upadhyay, G 2021, Applicability of Bobbin Tool Friction Stir Welding for Dissimilar Al-Mg Joint. in AK Parwani, PL Ramkumar, K Abhishek & SK Yadav (eds), Lecture Notes in Intelligent Transportation and Infrastructure: Proceedings of ICRAM 2020. Lecture Notes in Intelligent Transportation and Infrastructure, vol. Part F1363, Springer Nature, pp. 223-232, 2nd International Conference on Recent Advances in Mechanical Infrastructure - ICRAM 2020 , Ahmedabad, India, 21/08/20. https://doi.org/10.1007/978-981-33-4176-0_18

Applicability of Bobbin Tool Friction Stir Welding for Dissimilar Al-Mg Joint. / Jadav, Harshadkumar H.; Badheka, Vishvesh J.; Fuse, Kishan et al.
Lecture Notes in Intelligent Transportation and Infrastructure: Proceedings of ICRAM 2020. ed. / Ajit Kumar Parwani; PL. Ramkumar; Kumar Abhishek; Saurabh Kumar Yadav. Springer Nature, 2021. p. 223-232 (Lecture Notes in Intelligent Transportation and Infrastructure; Vol. Part F1363).

Research output: Chapter in Book/Report/Conference proceeding › Chapter

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AU - Jadav, Harshadkumar H.

AU - Badheka, Vishvesh J.

AU - Fuse, Kishan

AU - Mehta, Kush

AU - Upadhyay, Gautam

N1 - Funding Information: Acknowledgements The authors would like to thank the Student Research Program of Office of Research & Sponsored Program, Pandit Deendayal Petroleum University (PDPU), Gandhi-nagar, India, for providing necessary support and infrastructure to carry out this work under project No.: ORSP/R&D/SRP/2019-20/1454/61. The processing of samples was undertaken on a Vertical Machining Center procured under funding from the Indian Space Research Organisation, Department of Space, Government of India, Bangalore (in collaboration with Space Application Center, Ahmedabad) under the RESPOND program (Project number-ISRO/RES/4/567/09-10). Publisher Copyright: © 2021, The Author(s), under exclusive license to Springer Nature Singapore Pte Ltd. Jadav, H.H., Badheka, V.J., Fuse, K., Mehta, K., Upadhyay, G. (2021). Applicability of Bobbin Tool Friction Stir Welding for Dissimilar Al-Mg Joint. In: Parwani, A.K., Ramkumar, P., Abhishek, K., Yadav, S.K. (eds) Recent Advances in Mechanical Infrastructure. Lecture Notes in Intelligent Transportation and Infrastructure. Springer, Singapore. https://doi.org/10.1007/978-981-33-4176-0_18

PY - 2021/3/1

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N2 - Stringent material property demand for fuel economy in automobile and aerospace industry can be addressed only by either reducing weight or improving efficiency of the engine. Structural weight reduction requires dissimilar materials with varying thickness and geometry to be joined. Friction stir welding (FSW) is one of the latest additions to the joining processes. Bobbin tool friction stir welding (BTFSW) is a novel derivative of FSW process utilizing two shoulders for even heat distribution with advantage of eliminating backup support. This paper reports conventional FSW and feasibility trials of BTFSW for similar aluminum alloy (AA6061-T6), similar magnesium alloy (AZ31B) and dissimilar aluminum alloy (AA6061-T6) to magnesium alloy (AZ31B). Conventional FSW trials report successful welds without any observable surface defects. However, BTFSW weld surface presents defects like flash and groove, and material sticking to the tool pin is observed. Pin length, bigger diameter of the lower shoulder and flat surface of tool shoulder without chamfered edge are considered to be responsible for flash and groove defects. Process parameters which could have restricted joint formation are discussed. Though these feasibility trials of dissimilar aluminum and magnesium alloy BTFSW achieved limited success, it paves a path for successful joining using BTFSW.

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KW - aluminum alloy

KW - bobbin tool FSW

KW - dissimilar welding

KW - magnesium alloy

KW - reducing weight

KW - friction stir welding (FSW)

KW - bobbin tool friction stir welding (BTFSW)

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Jadav HH, Badheka VJ, Fuse K, Mehta K, Upadhyay G. Applicability of Bobbin Tool Friction Stir Welding for Dissimilar Al-Mg Joint. In Parwani AK, Ramkumar PL, Abhishek K, Yadav SK, editors, Lecture Notes in Intelligent Transportation and Infrastructure: Proceedings of ICRAM 2020. Springer Nature. 2021. p. 223-232. (Lecture Notes in Intelligent Transportation and Infrastructure). doi: 10.1007/978-981-33-4176-0_18

Applicability of Bobbin Tool Friction Stir Welding for Dissimilar Al-Mg Joint

Abstract

Publication series

Conference

Funding

Keywords

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